Methods for constructing a building and resulting building

ABSTRACT

The subject invention pertains to a method for constructing, transporting and erecting buildings. The subject invention also relates to buildings which can be transported and erected at a desired site. Advantageously, a specific embodiment of the subject invention can be relocatable. The subject invention is advantageous in situations where an individual or group, such as a school system or construction company, needs temporary, portable buildings which can easily be constructed and broken down for transportation to a new site. In a specific embodiment, the subject method utilizes durable construction materials to comply with building codes and withstand the rigors of years of service in a variety of environmental conditions in addition to providing rapid construction and relocation benefits.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser. No 10/096,011, filed Mar. 11, 2002, which claims the benefit of U.S. Provisional Application No. 60/274,890, filed Mar. 9, 2001, both of which are hereby incorporated by reference herein in their entirety, including any figures, tables, or drawings.

BACKGROUND OF THE INVENTION

Relocatable buildings have many wide ranging applications. Buildings of this type can be used to provide temporary and/or low cost shelter. In addition, the use of relocatable buildings can reduce the period of time necessary to erect a desired building. Relocatable buildings can be used by, for example, school systems as classroom buildings or on construction sites as temporary offices.

In addition to providing useful temporary shelter, relocatable buildings can be employed to solve long term needs of customers. School systems, for example, can purchase several relocatable buildings to aid with population booms within the system. In a school system, a certain district may have an overpopulation of elementary school students. The school system can place one or more relocatable buildings at the elementary schools with too many students. When the elementary school students move on to middle school, the school system can then relocate the buildings to the middle school in order to “follow the boom” of students. In this fashion, a school system can manage periodic shifts in populations without resorting to expensive, permanent school building renovation or expansion.

Due to the possibility that an individual or group may employ a relocatable building for an extended period of time, relocatable buildings preferably have a long life span and are of sturdy construction. Furthermore, certain applications necessitate additional performance criteria for the buildings. Also, certain jurisdictions may have building codes dealing with relocatable buildings, such as the ability to withstand high winds. Other considerations such as insulative properties, environmental impact, and weatherproofness influence the construction of relocatable buildings.

Traditional methods of constructing relocatable buildings include prefabricating portions of the building, transporting the portions to the construction site and putting the building together from the ground up. These traditional methods tend to be time consuming and require extensive labor to be located at the building site. Additionally, in order to relocate the building, an owner must employ a construction crew to tear-down the building and prepare it for transportation and reconstruction at the new site.

Accordingly, there is a need for a method for relocatable buildings which provides for a building to be constructed quickly and easily. There is also a need for a method of constructing a relocatable building which can be easily transported by a small group of workers rather than a full construction crew. Further, there is a need for a method of constructing a relocatable building combining the speed and simplicity of construction with quality material which will stand up to the environment for years to come and satisfy applicable building regulations.

BRIEF SUMMARY OF THE INVENTION

The subject invention pertains to a method for constructing, transporting, and erecting buildings. The subject invention also relates to buildings which can be transported and erected at a desired site. Advantageously, specific embodiments of the subject invention can be relocatable. The subject method can provide for simplified construction of relocatable buildings, such as those used as temporary classrooms or on construction sites. In a specific embodiment, the subject invention includes constructing a building section. Each building section can include a floor panel, a wall panel, end panels and roofing structures. The subject invention also provides for the joining of multiple building sections to form larger structures. Additionally, the subject construction method provides for structures which facilitate joining and separating the sections as needed for assembly or movement.

The subject method and apparatus can be used to shorten the time and labor required both to initially construct a building and also to relocate the building as needed. By using the subject invention, those who employ relocatable buildings can move them from site to site with a less labor intensive process than before. The subject relocatable buildings can be relocated with a lifting machine such as a crane and a mode of transport such as a truck.

The subject invention is advantageous in situations where, for example, a school system needs to adapt classroom capacity to the changing population of students within the system. Permanent renovations or additions to school buildings can be expensive and time consuming to implement, but by utilizing the subject relocatable buildings, school systems can shift classroom capacity inexpensively while still maintaining a high quality building for the students to use.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a building section in accordance with a specific embodiment of the subject invention.

FIG. 2 shows a foundation layout in accordance with a specific embodiment of the subject invention.

FIG. 3 shows the installation of a floor panel in accordance with a specific embodiment of the subject invention.

FIG. 4 shows the installation and attachment of a wall panel in accordance with a specific embodiment of the subject invention.

FIG. 5 shows the installation and attachment of end wall panels in accordance with a specific embodiment of the subject invention.

FIG. 6 shows the installation and attachment of a reinforcing structure in accordance with a specific embodiment of the subject invention.

FIG. 7 illustrates the installation of roofing support structures in accordance with a specific embodiment of the subject invention.

FIG. 8 illustrates the installation of insulating roofing material in accordance with a specific embodiment of the subject invention.

FIG. 9 illustrates an example of a building section with a roof attached in accordance with a specific embodiment of the subject invention.

FIG. 10 illustrates a building section in accordance with the subject invention after installation of a second wall panel.

FIG. 11 illustrates the attachment of two building sections to form a building module in accordance with a specific embodiment of the subject invention.

FIG. 12 illustrates the installation of relocation bracing structures in accordance with a specific embodiment of the subject invention.

FIG. 13 illustrates the lifting of one building section for transportation in accordance with a specific embodiment of the subject invention.

FIG. 14 illustrates the attachment of transportation structures to the relocatable building sections and the lifting of one section for transportation in accordance with a specific embodiment of the subject invention.

DETAILED DISCLOSURE OF THE INVENTION

The subject invention pertains to a method for constructing, transporting, and erecting buildings. The subject invention also relates to buildings which can be transported and erected at a desired site. Advantageously, a specific embodiment of the subject invention can be relocatable. The subject invention is advantageous in situations where an individual or group, such as a school system or construction company, needs temporary, portable buildings which can easily be constructed and broken down for transportation to a new site. In a specific embodiment, the subject method utilizes durable construction materials to comply with building codes and withstand the rigors of years of service in a variety of environmental conditions in addition to providing rapid construction and relocation benefits.

A preferred method of constructing a building according to the subject invention is now discussed. Most preferably, a building section built according to the subject invention is constructed at a centralized manufacturing site. The individual building sections can then be transported to the installation site where minimal reassembly is required prior to occupancy. A centralized manufacturing site allows for labor usage to be maximized and used more efficiently than constructing each relocatable building at the installation site from the ground up. It is important to note that the specific embodiment described herein relates to a relocatable building consisting of two separable sections which can be broken down and transported. It is understood that a building in accordance with the subject invention can be made from any number, or combination, of sections without deviating from the spirit of the invention.

FIG. 1 illustrates a building section 1 in accordance with an embodiment of the subject invention. In order to begin construction, the desired building section 1 size and capacity should be determined. Referring to FIG. 2, a preferred first step in construction of a building section 1 is forming a foundation layout 2 of appropriate size. Preferably, the foundation layout is made from concrete high-strength shim blocks 3, but any suitable material such as masonry blocks, wooden blocks or cinder blocks can be used without affecting the functionality of the invention. Alternatively, a foundation layout 2 suitable for construction can be any relatively hard and flat surface, such as packed soil, which is suitable for supporting the weight of the building section. Concrete block-out can be incorporated into the foundation layout 2 for transportation of structure.

Following the construction of the foundation layout 2, a floor panel 5 can be installed onto the foundation layout 2 as illustrated in FIG. 3. If desired, the floor panel 5 can be temporarily secured to the foundation layout 2 for added stability during the construction process. The floor panel 5 can be constructed of any durable material such as poured concrete, plywood, or plastic. Preferably, the floor panel is constructed of 7¼″ reinforced concrete panels which also have polystyrene insulation embedded during construction. Additionally, relocation notches 6, lifting insert 5 a, attachment 12, and plumbing opening 5 b can be incorporated into the floor panel 5 during manufacture.

As shown in FIG. 4, a wall panel 9 can be installed following the installation of the floor panel 5. The wall panel 9 can include openings 10 and roof supporting structure mounts/lifting embedments 11. Openings 10 can be installed for doors, windows, louvers or any other building access commonly needed in buildings of the type being constructed. The roof supporting structures 11 can be used to provide anchoring points for roof supports such as beams, straps or rods. The wall panel 9 is preferably constructed of a strong, durable building material such as poured concrete, wood or plastic. Most preferably, the wall panel 9 is constructed from a reinforced concrete-polystyrene composite, such as INSULWALL™ to provide a greater degree of high wind load resisting weatherproof performance and energy efficiency. The wall panel 9 can be attached to the floor panel 5 through any attachment structure 12 commonly used to join similar building materials such as straps, bolts, or welding. However, the most preferred embodiment uses several welded brackets to attach the wall panel 9 to the floor panel 5. Importantly, relocation bracing points 13 can be embedded in the wall panel 9 to supply anchoring points for aiding in lifting and transporting the building section 1. Installation bracing 9 a can be installed to support wall panel during installation.

Following installation of the wall panel 9, as shown in FIG. 5, a pair of end panels 15 can be installed and attached to the floor panel 5 and the wall panel 9. End panels 15 can be attached to the floor panel 5 and wall panel 9 in a similar fashion to the attachment previously described in attaching the wall panel 9 to the floor panel 5. End panels 15 can include openings 17 to allow access to the building section 1. Such openings 17 can facilitate, for example, duct installation, venting or electrical access to the building section 1. The end panels 15 can also include relocation bracing points 13 embedded in the end panels 15. The relocation bracing points 13 can provide additional anchoring points for lifting and transporting the building 1. If preferred, end panels 15 can be installed prior to wall panel 9, as would be apparent to one skilled in the art.

FIG. 6 shows the attachment of a reinforcing structure 19 which can be used to support the roof 25 of the building section 1. The reinforcing structure 19 can take the shape of any suitable structure, such as a bar joist, a truss, steel beam, concrete beam, or wood beam. The reinforcing structure 19 can be made from any suitable material such as steel, wood or plastic and attached to the end panels 15 through suitable attachment methods as previously described. Preferably, the reinforcing structure 19 is made from steel and welded to the end panels 15. Any number of reinforcing structures 19 can be used in construction of the building section 1 without affecting functionality, but preferably there is a floor panel to reinforcing structure ratio of 1:1.

FIG. 7 illustrates a building section 1 with sub-purlin roof supports 21 and X-bracing roof supports 22 installed according to a specific embodiment of the subject invention. Such a combination of sub-purlin 21 and X-bracing 22 roof supports can be used to enhance the structural stability of the roof. Roof supports 21 and 22 can be constructed from any suitable material such as steel, plastic or wood. Preferably, sub-purlin roof supports 21 and X-bracing roof supports 22 are made from steel and are secured between either the reinforcing structure 19 and a wall panel 9 or between the reinforcing structure 19 and an end panel 15. When attachments are made to the wall panel 9, the roof supports 21 and 22 can be secured to the roof supporting structure mounts 11 embedded in the wall panel 9.

To increase energy efficiency, an insulation cover 23 can be optionally installed over the roof supports 21. FIG. 8 shows a preferred example of a suitable insulation cover 23. The insulation cover 23 can be constructed of any material suitable for building insulation such as polystyrene, vinyl vapor retarder film or vinyl vapor laminate.

Once an appropriate insulation cover 23, is installed, the roof 25 can be attached over the building section 1 as shown in FIG. 9. If no insulation cover 23 is utilized, the roof 25 can be installed directly to supports 21 and 22. The roof 25 can be made from any suitable weatherproof roofing material such as reinforced concrete, composite deck, aluminum, steel, or traditional shingles.

Thus, a method for constructing a building section 1 according to the subject invention has been described. Additionally, the building section 1 of the subject invention can be prepared for transportation and installation at a new site in a short period of time and without an excess of labor intensive activity.

To prepare a building section 1 for occupancy, the present invention provides a wide degree of flexibility of configurations. The uncovered side of the building section 1 can be used to communicate with, for example, another wall panel 9 or another building section 1. In one embodiment, as shown in FIG. 10, a second wall panel 9 can be attached to the floor panel 5, end panels 15 and reinforcing structure 19. The second wall panel 9 can be attached to the floor panel 5, end panels 15 and reinforcing structure 19 in a similar manner as was previously described. In this fashion, a fully enclosed building can be fabricated from a building section 1 through one attachment step. It is understood that the shape and size of the wall panels 9 does not affect the functionality of the subject invention. For example, both wall panels 9 may be of equal size, or, of differing size as illustrated in FIG. 10.

In another specific embodiment, two or more building sections 1 may be combined in order to construct a building module 33 of increased size. For example, as illustrated in FIG. 11, two building sections 1, A and B can be attached to form a building module 33 twice the size of a single building section 1. In order to form a larger building, a corresponding foundation layout 2 is preferably formed in advance. Onto this foundation layout 2 the two building sections A and B can be lowered by a lifting machine, such as a crane. Each individual building section A and B can then be attached to the foundation layout 2 as described in the construction of a building section 1. Each building section A and B can then be attached to each other, floor panel 5 to floor panel 5, end panels 15 to end panels 15. The panel attachment is preferably done through welding, although other means of joining the building sections A and B will be apparent to those skilled in the art. Preferably, after all panels have been attached, a ridge cover plate 27 can be attached across the roof seam, providing a weatherproof barrier. Thus, a larger building module 33 can be constructed from the joining of multiple building sections 1. Alternatively, the construction of a building module 33 can begin with both building sections A and B being constructed simultaneously, in accordance with the methods provided in the subject invention, on a foundation layout 2 of appropriate size.

In order to prepare a building section 1, as shown in FIG. 1, for transportation to a new site, a method of preparing a building section 1 for transportation is also discussed. As shown in FIG. 12, a first step in preparing a building section 1 for transportation is to attach relocation bracing structures 29 to the building section 1 by using the embedded relocation bracing points 13 located in the wall panel 9, floor panel 5 and the end panels 15. The relocation bracing structures 29 can be made of any material suitable to support a building section 1, such as steel or wood. The relocation bracing structures 29 can be attached to the wall panel 9, floor panel 5 and/or end panels 15 through any appropriate attachment means, such as a welding, straps, or bolts. The floor panel 5 is preferably detached from the foundation layout 2 prior to transportation. Thus, as shown in a view of a building section 1 in FIG. 12, a building section 1 has been prepared for transportation by the installation of relocation bracing structures 29.

As shown in FIG. 13, to physically move the building section 1 to another site, transportation structures 31 can be used to lift the building section 1 from the foundation layout 2. The transportation structures 31 can attach to and/or around the floor panel 5 of the building section 1 by means of the relocation notches 6. The transportation structures 31 can be constructed of any material commonly used to lift heavy equipment, such as steel and can include straps, belts or beams. Thus, a crane or any other suitable machine for lifting, can be employed to lift the building section 1 from the foundation layout 2 and onto, for example, an awaiting flat bed truck or train car. The truck or train can then transport the building section 1 to the relocation site for reassembly.

When a building module 33 has been constructed, a similar process of transportation preparation can be used. When preparing a building module 33 for transportation, the ridge cover plate 27, if installed, is preferably removed first to ease the separation of the different building sections 1. FIG. 14 shows a building module 33 having building section B being lifted away for relocation while section A is prepared for lifting. In this specific embodiment, once building sections A and B are lifted away, the foundation layout 2 will remain in place. At this point, the foundation layout 2 can be used to construct another building module 33 or can be removed and shipped to the relocation site for installation.

Once the separate building sections A and B arrive at the relocation site, the sections can then be reassembled to prepare the building module 33 for occupancy. The foundation layout 2, generally, although not necessarily, a different foundation layout 2 than the one located at the construction site can be formed. Next, the separate sections A and B can be lowered into place and relocation braces 29 removed. Once the transportation structures 31 and the relocation braces 29 are removed, the ridge cover plate 27 can be reinstalled and the building module 33 is ready to be attached to the foundation layout 2 and for finishing preparations such as carpeting, air conditioning and electricity to be installed prior to occupancy. A similar method can be utilized in installing a single building section 1. The foundation layout 2 corresponding to the building section 1 can be formed and the single building section 1 can be lowered onto the foundation layout 2. The building section 1 can then be attached to the foundation layout 2 and the final wall panel 9 can be secured in place, if not already attached prior to transportation. The finished building can then be prepared for occupancy as described above.

All patents, patent applications, provisional applications, and publications referred to or cited herein are incorporated by reference in their entirety, including all figures and tables, to the extent they are not inconsistent with the explicit teachings of this specification.

It should be understood that the example and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and the scope of the appended claims. 

1. A method for preparing a transportable building section, comprising: forming a foundation layout upon which a transportable building section can be constructed; positioning a floor panel on the foundation layout; attaching a wall panel to a first side of the floor panel; attaching a first end panel to a first end of the floor panel; attaching a second end panel to a second end of the floor panel; securing each of the end panels to the wall panel; and attaching at least one bracing structure, wherein each of the at least one bracing structure is attached by attaching the bracing structure to at least two of the wall panel, floor panel, the first end panel, and the second end panel.
 2. The method according to claim 1, wherein attaching a wall panel to a first side of the floor panel is performed after attaching a first end panel to a first end of the floor panel.
 3. The method according to claim 2, wherein attaching a wall panel to a first side of the floor panel is performed after attaching a second end panel to a second end of the floor panel.
 4. The method according to claim 1, wherein attaching at least one bracing structure comprises attaching at least one end of the at least one bracing structure to a relocation bracing point on the wall panel, the floor panel, or the first end panel, or the second end panel to which the at least one bracing structure is attached.
 5. The method according to claim 1, further comprising: attaching the floor panel to the foundation layout after positioning the floor panel on the foundation layout and detaching the floor panel from the foundation layout prior to transporting the transportable building section.
 6. The method according to claim 1, further comprising: attaching at least one transportation structure to a corresponding at least one relocation notch of the floor panel wherein lifting the at least one transportation structure lifts the transportable building section.
 7. The method according to claim 6, further comprising: transporting said transportable building section to a desired installation location.
 8. The method according to claim 1, further comprising: attaching a reinforcing structure, wherein the reinforcing structure is capable of supporting a roof.
 9. The method according to claim 8, wherein attaching a reinforcing structure comprises attaching a first end of the reinforcing structure to the first end panel and attaching a second end of the reinforcing structure to the second end panel.
 10. The method according to claim 9, further comprising: attaching roof support structure between the first end panel and the second end panel.
 11. The method according to claim 9, further comprising: attaching roof support structures between the reinforcing structure and the wall panel.
 12. The method according to claim 11, further comprising: attaching additional roof support structures between the first end panel and the second end panel.
 13. The method according to claim 12, further comprising: attaching a roof structure to the first end panel, the second end panel, and the wall panel.
 14. The method according to claim 1, wherein the floor panel comprises concrete.
 15. The method according to claim 1, wherein at least one of the wall panel, the first end panel, and the second end panel comprises concrete.
 16. The method according to claim 1, wherein at least one of the wall panel, the first end panel, and the second end panel comprise a reinforced concrete-polystyrene composite.
 17. The method according to claim 9, wherein the roof support structure comprises x-bracing root supports.
 18. The method according to claim 1, wherein the floor panel comprises reinforced concrete and polystyrene insulation.
 19. The method according to claim 1, wherein at least one of the wall panel, the first end panel, and the second end panel comprises reinforced concrete.
 20. The method according to claim 19, wherein the at least one of the wall panel, the first end panel, the second end panel comprises reinforced polystyrene insulation. 